Heads-Up Display and Coating Therefor

ABSTRACT

A laminate including: a first ply having a first surface and a second surface, where the first surface is an outer surface of the laminate; a second ply having a third surface facing the second surface and a fourth surface opposite the third surface, where the fourth surface is an inner surface of the laminate; an interlayer between the plies; and an enhanced p-polarized reflective coating positioned over at least a portion of a surface of the plies. When the laminate is contacted with radiation having p-polarized radiation at an angle of 60° relative to normal of the laminate, the laminate exhibits a LTA of at least 70% and a reflectivity of the p-polarized radiation of at least 10%. A display system and method of projecting an image in a heads-up display is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/989,188 filed Aug. 10, 2020, which is a continuation of U.S.patent application Ser. No. 16/111,496, filed Aug. 24, 2018, whichissued on Sep. 29, 2020 as U.S. Pat. No. 10,788,667, which claimspriority to and the full benefit of U.S. Provisional Patent ApplicationNo. 62/552,467, filed on Aug. 31, 2017; the disclosures of which arehereby incorporate by reference in their entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a laminate having enhanced p-polarizedradiation reflecting properties, a display system for projecting animage, and a method of projecting an image in a heads-up display.

Description of Related Art

Conventional automotive heads-up displays (HUDs) use an electromagneticradiation source in the dashboard that projects light up onto thewindshield, which is then reflected to the driver's eyes, creating avirtual image of vehicle data so that the driver has access toinformation about the vehicle's operation without having to look awayfrom the road. For electromagnetic radiation reflecting off of thewindshield at angles typically found in a conventional vehicle, and atypical unpolarized light source, such as a light emitting diode (LED),the reflected light primarily is s-polarized, with a much smallercomponent of the light being p-polarized. In the extreme case, if theangle of incidence of the electromagnetic radiation to the windshield isthe Brewster's angle of an air to glass interface (approximately 57°),the p-polarized reflectance is zero percent.

Light from the radiation source (primarily s-polarized) will reflect offof both the innermost surface of the windshield and the outermostsurface of the windshield due to the index mismatch between air andglass. This leads to two reflected images being formed, one from eachsurface. Multiple images formed in a HUD is a phenomenon referred to as“ghosting”, and eliminating or minimizing the presence of “ghosts” is agoal of HUD technology. A conventional method of resolving ghosting isby employing a wedge-shaped vinyl layer between the inner and outerglass plies of the windshield to adjust the geometry of the two glassplies to align the two reflected images. This wedge-shaped vinylincreases the cost of the windshield and also increases the complexityof manufacturing the windshield.

It is also desirable to apply a coating to at least one of the glassplies to provide solar control, heating, and/or antenna functionality tothe windshield. This additional coating leads to a third index mismatchwithin the windshield, which leads to a third reflection, and a thirdreflected image on the HUD system, which is difficult to be compensatedfor by the wedge-shaped vinyl layer.

Another problem with conventional HUD systems results from the fact thatmany drivers wear polarized sunglasses to reduce glare from the road andother sources while driving. Typical polarized sunglasses work byblocking s-polarized radiation. P-polarized radiation is able to passthrough the polarized sunglasses. However, as mentioned above, inconventional HUD systems, s-polarized radiation is primarily whatreflects off of the windshield to form the image of the HUD, and verylittle p-polarized radiation is reflected off of the windshieldsurfaces. This is especially true considering the windshield istypically positioned at an angle near the Brewster's angle for the airto glass interface. Thus, a driver wearing conventional polarizedsunglasses may not be able to see the image of the HUD formed by theprimarily s-polarized radiation.

Therefore, there is a need in the art for a system and/or components toreduce or eliminate one or more of these problems. For example, it wouldbe desirable to provide a HUD system that projects an image viewable todrivers wearing polarized sunglasses and/or that reduces or eliminatesghosting.

SUMMARY OF THE INVENTION

The present invention is directed to a laminate, such as a windshield,having enhanced p-polarized radiation reflecting properties. Thelaminate includes a first ply having a first surface (No. 1 surface) anda second surface (No. 2 surface) opposite the first surface, where thefirst surface is an outer surface of the laminate; a second ply having athird surface (No. 3 surface) facing the second surface and a fourthsurface (No. 4 surface) opposite the third surface, where the fourthsurface is an inner surface of the laminate. An interlayer is locatedbetween the first ply and the second ply. An enhanced p-polarizedreflective coating of the invention is located over at least a portionof at least one of the surfaces of the first ply and/or the second ply.When the laminate is contacted with radiation from a radiation source,the radiation having p-polarized radiation, at an angle of 60° relativeto normal of the laminate, the laminate exhibits a luminoustransmittance using standard illuminate A (LTA) value of at least 70%and a reflectivity of the p-polarized radiation of at least 5%, such asat least 10%.

The enhanced p-polarized reflective coating may include a plurality oflayers. The enhanced p-polarized reflective coating may be positionedover at least a portion of the second surface or the third surface. Theenhanced p-polarized reflective coating may include: a base layerpositioned over the portion of the at least one of the surfaces; a firstmetal functional layer positioned over at least a portion of the baselayer; a first sacrificial metal layer positioned over at least aportion of the first metal functional layer; a first phase adjustmentlayer positioned over at least a portion of the first sacrificial metallayer; a second metal functional layer positioned over at least aportion of the first phase adjustment layer; a second sacrificial metallayer positioned over at least a portion of the second metal functionallayer; a topcoat layer positioned over at least a portion of the secondsacrificial metal layer; and an overcoat positioned over at least aportion of the topcoat layer. The enhanced p-polarized reflectivecoating may further include: a second phase adjustment layer positionedover at least a portion of the second sacrificial metal layer; a thirdmetal functional layer positioned over at least a portion of the secondphase adjustment layer; a third sacrificial metal layer positioned overat least a portion of the third metal functional layer; the topcoatlayer positioned over at least a portion of the third sacrificial metallayer; and the overcoat positioned over at least a portion of thetopcoat layer.

The base layer may include: a first film including a metal alloy oxidefilm; and a second film positioned over the first film of the baselayer, the second film of the base layer including an oxide film. Thefirst film of the base layer may include a zinc/tin alloy oxide,particularly zinc stannate. The second film of the base layer mayinclude a metal oxide film, particularly zinc oxide. In one example, thebase layer may have a thickness in the range of 300-500 angstroms,preferably 350-430 angstroms. In another example, the base layer mayhave a thickness in the range of 350-550 angstroms, preferably 420-500angstroms.

The first phase adjustment layer and/or the second phase adjustmentlayer may include: a first film including an oxide film; a second filmpositioned over the first film of the first phase adjustment layerand/or the second phase adjustment layer, the second film of the firstphase adjustment layer and/or the second phase adjustment layerincluding a metal alloy oxide film; and a third film positioned over thesecond film of the first phase adjustment layer and/or the second phaseadjustment layer, the third film of the first phase adjustment layerand/or the second phase adjustment layer including an oxide film. Thefirst film of the first phase adjustment layer and/or the second phaseadjustment layer and/or the third film of the first phase adjustmentlayer and/or the second phase adjustment layer may include a metal oxidefilm, particularly zinc oxide. The second film of the first phaseadjustment layer and/or the second phase adjustment layer may include azinc/tin alloy oxide, particularly zinc stannate. In one example, thefirst phase adjustment layer may have a thickness in the range of700-1,100 angstroms, preferably 850-1,050 angstroms. In another example,the first phase adjustment layer may have a thickness in the range of600-1000 angstroms, preferably 675-875 angstroms. The second phaseadjustment layer may have a thickness in the range of 500-1,000angstroms, preferably 600-850 angstroms.

The first metal functional layer, the second metal functional layer,and/or the third metal functional layer may include at least one nobleor near noble metal, particularly selected from silver, gold, platinum,palladium, osmium, iridium, rhodium, ruthenium, copper, mercury,rhenium, aluminum, and combinations thereof, more particularly metallicsilver. The first metal functional layer may have a thickness in therange of 10-200 angstroms, preferably 50-150 angstroms. The first metalfunctional layer may have a thickness in the range of 10-150 angstroms,preferably 50-110 angstroms. The second metal functional layer may havea thickness in the range of 10-150 angstroms, preferably 50-125angstroms. The second metal functional layer may have a thickness in therange of 10-100 angstroms, preferably 50-75 angstroms. The third metalfunctional layer may have a thickness in the range of 50-200 angstroms,preferably 75-150 angstroms.

The first sacrificial metal layer, the second sacrificial metal layer,and/or the third sacrificial metal layer may include at least one oftitanium, niobium, tungsten, nickel, chromium, iron, tantalum,zirconium, aluminum, silicon, indium, tin, zinc, molybdenum, hafnium,bismuth, vanadium, manganese, and combinations thereof, particularlytitanium. The first sacrificial metal layer, the second sacrificialmetal layer, and/or the third sacrificial metal layer may have athickness in the range of 10-50 angstroms, preferably 20-40 angstroms,more preferably 25-35 angstroms.

The topcoat layer may include: a first film including an oxide film; anda second film positioned over the first film of the topcoat layer, thesecond film of the topcoat layer including a metal-alloy oxide film. Thefirst film of the topcoat layer may include a metal oxide film,particularly zinc oxide. The second film of the topcoat layer mayinclude a zinc/tin alloy oxide, particularly zinc stannate. The topcoatlayer may have a thickness in the range of 300-400 angstroms, preferably340-375 angstroms. The topcoat layer may have a thickness in the rangeof 275-450 angstroms, preferably 300-415 angstroms.

The overcoat may include a combination silica and alumina coating. Theovercoat may have a thickness in the range of 100-1,000 angstroms,preferably 600-800 angstroms.

The laminate 12 may further include an anti-reflective coatingpositioned over at least a portion of the first surface or the fourthsurface. The anti-reflective coating may be positioned over at least aportion of the first surface or the fourth surface. The first ply andthe second ply may be non-parallel relative to one another. Theinterlayer may be a wedge-shaped interlayer. The interlayer may be alayer of uniform thickness. The interlayer may include polyvinyl butyral(PVB). When contacted with the radiation from the radiation source, atan angle of 60° relative to normal of the laminate, the laminate mayexhibit a total reflectivity of up to 60%, preferably up to 55%, morepreferably up to 52%. The laminate may be an automotive laminate.

The present invention is also directed to a display system forprojecting an image including a laminate having enhanced p-polarizedradiation reflecting properties. The laminate includes: a first plyhaving a first surface and a second surface opposite the first surface,where the first surface is an outer surface of the laminate; a secondply having a third surface facing the second surface and a fourthsurface opposite the third surface, where the fourth surface is an innersurface of the laminate; an interlayer positioned between the first plyand the second ply; and an enhanced p-polarized reflective coatingpositioned over at least a portion of at least one of the surfaces ofthe first ply and/or the second ply. When the laminate is contacted withradiation from a radiation source, the radiation having p-polarizedradiation, at an angle of 60° relative to normal of the laminate, thelaminate exhibits a luminous transmittance using standard illuminate A(LTA) value of at least 70% and a reflectance of the p-polarizedradiation of at least 10%. The display system also includes a radiationsource directed at the laminate, the radiation source emitting radiationhaving p-polarized radiation.

The system may further include a polarized filter positioned between theradiation source and the laminate and may be configured to allow atleast a portion of the p-polarized radiation to pass therethrough. Thepolarized filter may filter at least a portion of s-polarized radiationemitted from the radiation source. The polarized filter may filtersubstantially all of the s-polarized radiation emitted from theradiation source. The radiation source may emit the radiation directedat the laminate such that an image is projected to an area of an innerside of the laminate. The image may be at least one of: a static imageor a dynamic image. The image may include a color. The image may be animage in a heads-up display. The laminate may be an automotive laminate,such as an automotive windshield. The enhanced p-polarized reflectivecoating may be positioned over at least a portion of the second surfaceor a portion of the third surface. The enhanced p-polarized reflectivecoating may be positioned over at least a portion of the first surfaceor a portion of the fourth surface. The enhanced p-polarized reflectivecoating may be positioned over at least a portion of the fourth surface,and the radiation source directed at the laminate may be positioned atan angle relative to the laminate such that the radiation contacts thefirst surface at an angle substantially equal to a Brewster's angle fora first surface-air interface.

The present invention is also directed to a method of projecting animage in a heads-up display including providing a laminate havingenhanced p-polarized radiation reflecting properties. The laminateincludes: a first ply having a first surface and a second surfaceopposite the first surface, where the first surface is an outer surfaceof the laminate; a second ply having a third surface facing the secondsurface and a fourth surface opposite the third surface, where thefourth surface is an inner surface of the laminate; an interlayerlocated between the first ply and the second ply; and an enhancedp-polarized reflective coating positioned over at least a portion of atleast one of the surfaces of the first ply and/or the second ply. Whenthe laminate is contacted with radiation from a radiation source, theradiation having p-polarized radiation, at an angle of 60° relative tonormal of the laminate, the laminate exhibits a luminous transmittanceusing standard illuminate A (LTA) value of at least 70% and areflectivity of the p-polarized radiation of at least 10%. The laminatealso includes directing the radiation source, emitting the radiationhaving p-polarized radiation, at the laminate, such that an image isprojected to an area of an inner side of the laminate.

These and other features and characteristics of the present invention,as well as the methods of operation and functions of the relatedelements of structures and the combination of parts and economies ofmanufacture, will become more apparent upon consideration of thefollowing description and the appended claims with reference to theaccompanying drawings, all of which form a part of this specification,wherein like reference numerals designate corresponding parts in thevarious figures. It is to be expressly understood, however, that thedrawings are for the purpose of illustration and description only andare not intended as a definition of the limits of the invention. As usedin the specification and the claims, the singular form of “a”, “an”, and“the” include plural referents unless the context clearly dictatesotherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view (not to scale) of a display systemincluding a laminate and a radiation source;

FIGS. 2A-2F are side views (not to scale) of various examples of alaminate having an enhanced p-polarized reflective coating;

FIGS. 3A and 3B are side views (not to scale) of enhanced p-polarizedreflective coatings located over a substrate, the enhanced p-polarizedreflective coatings including two metal functional layers;

FIGS. 4A and 4B are side views (not to scale) of enhanced p-polarizedreflective coatings located over a substrate, the enhanced p-polarizedreflective coatings including three metal functional layers;

FIG. 5A is a side view (not to scale) of a laminate including two pliesand having a wedge-shaped interlayer;

FIG. 5B is a side view (not to scale) of a laminate including two plieshaving an interlayer of continuous thickness;

FIG. 6 is a perspective view (not to scale) of a laminate having anenhanced p-polarized reflective coating on a fourth surface and aradiation source positioned such that radiation from the radiationsource contacts a first surface of the laminate at a Brewster's angle ofa first surface to air interface; and

FIG. 7 is a perspective view (not to scale) of a test apparatus forwhich radiation from a radiation source contacts a laminate at an angleof 60° relative to normal of the laminate.

DESCRIPTION OF THE INVENTION

For purposes of the description hereinafter, the terms “end”, “upper”,“lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”,“lateral”, “longitudinal”, and derivatives thereof shall relate to theinvention as it is oriented in the drawing figures. However, it is to beunderstood that the invention may assume various alternative variationsand step sequences, except where expressly specified to the contrary. Itis also to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification, are simply exemplary embodiments or aspects of theinvention. Hence, specific dimensions and other physical characteristicsrelated to the embodiments or aspects disclosed herein are not to beconsidered as limiting.

For purposes of the following detailed description, it is to beunderstood that the invention may assume various alternative variationsand step sequences, except where expressly specified to the contrary.Moreover, other than in any operating examples, or where otherwiseindicated, all numbers used in the specification and claims are to beunderstood as being modified in all instances by the term “about”.Accordingly, unless indicated to the contrary, the numerical parametersset forth in the following specification and attached claims areapproximations that may vary depending upon the desired properties to beobtained by the present invention. At the very least, and not as anattempt to limit the application of the doctrine of equivalents to thescope of the claims, each numerical parameter should at least beconstrued in light of the number of reported significant digits and byapplying ordinary rounding techniques.

It should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between (andincluding) the recited minimum value of 1 and the recited maximum valueof 10, that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10.

With respect to coating layers described herein, the term “over” meansfarther from the substrate on which the coating layer is positioned. Forexample, a second layer positioned “over” a first layer means that thesecond layer is positioned farther from the substrate than is the firstlayer. The second layer may be in direct contact with the first layer.Alternatively, one or more other layers may be positioned between thefirst layer and the second layer.

The term “film” means a region having a distinct composition. A “layer”may include one or more “films”. A “coating” may include one or more“layers”.

The terms “polymer” or “polymeric” include oligomers, homopolymers,copolymers, and terpolymers, e.g., polymers formed from two or moretypes of monomers or polymers.

The term “ultraviolet radiation” means electromagnetic radiation havinga wavelength in the range of 100 nm to less than 300 nm. The term“visible radiation” means electromagnetic radiation having a wavelengthin the range of 380 nm to 780 nm. The term “infrared radiation” meanselectromagnetic radiation having a wavelength in the range of greaterthan 780 nm to 100,000 nm. The term “solar infrared radiation” meanselectromagnetic radiation having a wavelength in the range of 1,000 nmto 3,000 nm. The term “thermal infrared radiation” means electromagneticradiation having a wavelength in the range of greater than 3,000 nm to20,000 nm.

The terms “metal” and “metal oxide” include silicon and silica,respectively, as well as traditionally recognized metals and metaloxides, even though silicon conventionally may not be considered ametal.

By “at least” is meant “greater than or equal to”. By “not greater than”is meant “less than or equal to”.

The term “includes” is synonymous with “comprises”.

A “reference laminated unit” is defined as a laminate having two piecesof 2 mm clear float glass separated by a 0.76 mm layer of PVB with theenhanced p-polarized reflective coating on the No. 3 surface. By“reference laminated value” is meant the reported value, e.g., LTA,reflectance, etc., measured for the laminated unit using the testapparatus shown in FIG. 7 .

The discussion of the invention may describe certain features as being“particularly” or “preferably” within certain limitations (e.g.,“preferably”, “more preferably”, or “even more preferably”, withincertain limitations). It is to be understood that the invention is notlimited to these particular or preferred limitations but encompasses theentire scope of the disclosure.

Display System

Referring to FIG. 1 , a display system 10 according to the presentinvention is shown. The display system 10 may be a heads-up display(HUD) in a vehicle, such as a heads-up display in an automobile oraircraft. However, the display system 10 is not limited to heads-updisplays in vehicles, and may be any type of display projecting animage. Non-limiting examples of displays that may be considered the“display system” include advertising, promotional, or informationaldisplays, and the like. The display system 10 may project an imagevisible to humans (e.g., within the visible spectrum). Alternatively,the display system 10 may project an image in a non-visible region ofthe electromagnetic spectrum.

With continued reference to FIG. 1 , the display system 10 may include alaminate 12 and a radiation source 14. The radiation source 14 may emitelectromagnetic radiation 16. The radiation source 14 may emit radiation16 across the entire radiation spectrum, or across only a portionthereof (e.g., across the visible spectrum, ultra violet radiation,infrared radiation, and the like, as well as combinations thereof). Theradiation source 14 may emit white light as the radiation 16. Theradiation 16 may include s-polarized radiation and/or p-polarizedradiation. By “s-polarized radiation” it is meant that the radiation 16has an electric field normal to the plane of incidence. By “p-polarizedradiation” it is meant that the radiation 16 has an electric field alongthe plane of incidence. “Angle of incidence” is defined as the anglebetween a ray of radiation incident on a surface to a line normal to thesurface at the point of incidence. The radiation source 14 may emitradiation 16 directed at the laminate 12 such that the radiation 16contacts the laminate 12 at at least one point.

With continued reference to FIG. 1 , the display system 10 may furtherinclude a polarized filter 18. The polarized filter 18 may be positionedbetween the radiation source 14 and the laminate 12. The polarizedfilter 18 may allow at least a portion of the p-polarized and/or thes-polarized radiation to pass therethrough. The polarized filter 18 mayonly allow p-polarized radiation to pass therethrough. The polarizedfilter 18 may filter at least a portion of the s-polarized radiation,such that the filtered portion cannot pass therethrough. The polarizedfilter 18 may filter substantially all of the s-polarized radiation,such that substantially all of the s-polarized radiation cannot passtherethrough. Substantially all, in this context, means that thepolarized filter 18 filters at least 95% of the s-polarized radiation,such as at least 97%, at least 99%, or 100% of the s-polarizedradiation.

With continued reference to FIG. 1 , the radiation source 14 may emitradiation 16 that directs off of the laminate 12, such that at least aportion of the radiation 16 is reflected off of the laminate 12 and isdirected to an eye 20 of a user. The portion of the radiation notreflected off of the laminate 12, may be refracted, absorbed, orotherwise transmitted through the laminate 12. The user may be wearingpolarized sunglasses 21, and the radiation 16 directed to the eye 20 ofthe user may be directed toward the polarized sunglasses 21. Thepolarized sunglasses 21 may filter s-polarized radiation such that atleast a portion of the s-polarized radiation cannot pass therethrough.

With continued reference to FIG. 1 , when the radiation source 14 emitsthe radiation 16 directed at the laminate 12, an image may be projectedto an area on an inner side of the laminate 12, and the image may beviewable to the eye 20 of the user. The image of the display system 10may be static or dynamic. The image may include colors and may be amonochromatic image or a polychromatic image. The image may be an imagein a HUD. The HUD may be a HUD in an automobile or other vehicle. Inthis example, the laminate 12 may be a windshield, or other laminate 12in the vehicle, and the radiation source 14 may be directed at thelaminate 12 to display an image so that the driver (or other user) maysee the image while operating the vehicle.

Laminate

Referring to FIG. 1 and FIGS. 2A-2F, various examples of laminates 12 ofthe present invention are shown. The laminate 12 may include a first ply22 having a first surface 24 (No. 1 surface) and an opposite secondsurface 26 (No. 2 surface). The laminate 12 may also include a secondply 28 having a third surface 30 (No. 3 surface) and an opposite fourthsurface 32 No. 4 surface). This numbering of the surfaces is in keepingwith standard practice in the art. The second surface 26 may be facingthe third surface 30, and an interlayer 34 may be positioned between thesecond surface 26 and the third surface 30. Referring to FIG. 1 , thefirst surface 24 may be an outer surface of the laminate 12, and thefourth surface 32 may be an inner surface of the laminate 12. In thecase of the laminate 12 being a windshield of a vehicle, the firstsurface 24 may be the surface closest to the sun, while the fourthsurface 32 may be the surface closest to an interior of the vehicle. Inthis way, the fourth surface 32 may be the surface of the laminate 12closest to the radiation source 14 positioned inside the vehicle anddirected at the laminate 12.

The first ply 22 and/or the second ply 28 may be transparent ortranslucent to visible radiation. By “transparent” is meant havingvisible radiation transmittance of greater than 0% up to 100%.Alternatively, the ply may be translucent. By “translucent” is meantdiffusing visible radiation such that objects on the side opposite aviewer are not clearly visible. Examples of suitable materials include,but are not limited to, plastic substrates (such as acrylic polymers,such as polyacrylates; polyalkylmethacrylates, such aspolymethylmethacrylates, polyethylmethacrylates,polypropylmethacrylates, and the like; polyurethanes; polycarbonates;polyalkylterephthalates, such as polyethyleneterephthalate (PET),polypropyleneterephthalates, polybutyleneterephthalates, and the like;polysiloxane-containing polymers; or copolymers of any monomers forpreparing these, or any mixtures thereof); ceramic substrates; glasssubstrates; or mixtures or combinations of any of the above. Forexample, the plies 22, 28 may include conventional soda-lime-silicateglass, borosilicate glass, or leaded glass. The glass may be clearglass. By “clear glass” is meant non-tinted or non-colored glass.Alternatively, the glass may be tinted or otherwise colored glass. Theglass may be annealed or heat-treated glass. As used herein, the term“heat treated” means tempered or at least partially tempered. The glassmay be of any type, such as conventional float glass, and may be of anycomposition having any optical properties, e.g., any value of visibleradiation transmittance, ultraviolet radiation transmittance, infraredradiation transmittance, and/or total solar energy transmittance. By“float glass” is meant glass formed by a conventional float process inwhich molten glass is deposited onto a molten metal bath andcontrollably cooled to form a float glass ribbon.

The first ply and/or the second ply 22, 28 may be, for example, clearfloat glass or may be tinted or colored glass. The plies 22, 28 may beof any desired dimensions, e.g., length, width, shape, or thickness.Non-limiting examples of glass that may be used for the practice of theinvention include clear glass, Starphire®, Solargreen®, Solextra®,GL-20®, GL-35™, Solarbronze®, Solargray® glass, Pacifica® glass,SolarBlue® glass, and Optiblue® glass, all commercially available fromVitro Architectural Glass of Pittsburgh, Pa.

The other of the first ply 22 and the second ply 28 may be of any of thematerials described above for the first ply 22 and/or the second ply 28.The first ply 22 and the second ply 28 may be the same or different fromone another. The first and second plies 22, 28 may each be, for example,clear float glass or may be tinted or colored glass or one ply 22, 28may be clear glass and the other ply 22, 28 colored glass.

With continued reference to FIGS. 2A-2F, the laminate 12 may alsoinclude an enhanced p-polarized reflective coating 36 positioned over atleast a portion of one of the surfaces 24, 26, 30, 32 of the plies 22,28. In FIG. 2A, the enhanced p-polarized reflective coating 36 ispositioned over the first surface 24. In FIG. 2B, the enhancedp-polarized reflective coating 36 is positioned over the second surface26. In FIG. 2C, the enhanced p-polarized reflective coating 36 ispositioned over the third surface 30. In FIG. 2D, the enhancedp-polarized reflective coating 36 is positioned over the fourth surface32.

With continued reference to FIGS. 2E-2F, the laminate 12 may includefurther coating layers beyond the enhanced p-polarized reflectivecoating 36. The laminate 12 may include an anti-reflective coating 38positioned over one of the surfaces 24, 26, 30, 32 of the plies 22, 28.As shown in FIGS. 2E and 2F, the anti-reflective coating 38 may bepositioned over the fourth surface 32 when the enhanced p-polarizedreflective coating 36 is positioned over the second surface 26 (FIG. 2E)or the third surface 30 (FIG. 2F).

Enhanced P-Polarized Reflective Coating

Referring to FIGS. 3A and 3B, the enhanced p-polarized reflectivecoating 36 may be a double metal functional layer enhanced p-polarizedreflective coating 36. In the double metal functional layer enhancedp-polarized reflective coating 36, a base layer 44 may be positionedover a substrate 42 (the substrate 42 being one of thepreviously-described surfaces 24, 26, 30, 32). A first metal functionallayer 46 may be positioned over the base layer 44. A first sacrificialmetal layer 48 may be positioned over the first metal functional layer46. A first phase adjustment layer 50 may be positioned over the firstsacrificial metal layer 48. A second metal functional layer 52 may bemay be positioned over the first phase adjustment layer 50. A secondsacrificial metal layer 54 may be positioned over the second metalfunctional layer 52. A topcoat layer 56 may be positioned over thesecond sacrificial metal layer 54. An overcoat 58 may be positioned overthe topcoat layer 56.

Referring to FIG. 3B, at least one of the layers in the enhancedp-polarized reflective coating 36 of the double metal functional layerenhanced p-polarized reflective coating 36 may include multiple layers.The base layer 44 may include a first film 66 and a second film 68. Thefirst film 66 may be positioned over the substrate 42, and the secondfilm 68 may be positioned over the first film 66. The first phaseadjustment layer 50 may include a first film 70, a second film 72, and athird film 74. The first film 70 may be positioned over the firstsacrificial metal layer 48. The second film 72 may be positioned overthe first film 70, and the third film 74 may be positioned over thesecond film 72. The topcoat layer 56 may include a first film 76 and asecond film 78. The first film 76 may be positioned over the secondsacrificial metal layer 54, and the second film 78 may be positionedover the first film 76.

Referring to FIGS. 4A and 4B, the enhanced p-polarized reflectivecoating 36 may be a triple metal functional enhanced reflective coating36, which includes several additional layers compared to the doublemetal functional layer enhanced p-polarized reflective coating 36 ofFIGS. 3A and 3B. The triple metal functional enhanced p-polarizedreflective coating 36 may further include (compared to the double metalfunctional layer enhanced p-polarized reflective coating 36) a secondphase adjustment layer 60 positioned over the second sacrificial metallayer 54. A third metal functional layer 62 may be positioned over thesecond phase adjustment layer 60. A third sacrificial metal layer 64 maybe positioned over the third metal functional layer 62. The topcoatlayer 56 and the overcoat layer 58 (previously described) may bepositioned over the third sacrificial metal layer 64.

Referring to FIG. 4B, at least one of the layers in the enhancedp-polarized reflective coating 36 of the triple metal functional layerenhanced p-polarized reflective coating 36 may include multiple layers.In addition to those described in the double metal functional layerenhanced p-polarized reflective coating 36 (FIG. 3B), the second phaseadjustment layer 60 of the triple metal functional layer enhancedp-polarized reflective coating 36 may have multiple layers. The secondphase adjustment layer 60 may include a first film 80, a second film 82,and a third film 84. The first film 80 may be positioned over the secondsacrificial metal layer 54. The second film 82 may be positioned overthe first film 80, and the third film 84 may be positioned over thesecond film 82. In the multi-layer topcoat layer 56 previouslydescribed, the first film 76 may be positioned over the thirdsacrificial metal layer 64.

Based on this disclosure, it will be appreciated that further repeatingcoating units are within the scope of the invention. For example, addingadditional phase adjustment layers, metal functional layers, and/orsacrificial metal layers (e.g., to form quadruple, quintuple, and thelike, metal functional layer enhanced p-polarized reflective coatings36) is also contemplated by this disclosure.

The enhanced p-polarized reflective coating 36 may be anelectroconductive low emissivity coating that allows visible wavelengthenergy to be transmitted through the coating but reflects longerwavelength solar infrared energy. By “low emissivity” is meantemissivity less than 0.4, such as less than 0.3, such as less than 0.2,such as less than 0.1, e.g., less than or equal to 0.05.

The enhanced p-polarized reflective coating 36, when applied to thesubstrate 42, may make the substrate 42 neutral in color such that thereflectivity for color value a* and/or b* is between −2 and 2, inaccordance with 1976 CIELAB color system specified by the InternationalCommission on Illumination. The substrate 42 may have a low exteriorreflectance, such that the reflectance is less than or equal to 30%,such as less than or equal to 15%, when observing the substrate 42 froman angle normal to the substrate 42.

The enhanced p-polarized reflective coating 36 may be deposited on thesubstrate 42 by any conventional method. Examples of such methodsinclude conventional chemical vapor deposition (CVD) and/or physicalvapor deposition (PVD) methods. Examples of CVD processes include spraypyrolysis. Examples of PVD processes include electron beam evaporationand vacuum sputtering (such as magnetron sputter vapor deposition(MSVD)). Other coating methods could also be used, such as, but notlimited to, sol-gel deposition. In one non-limiting embodiment, theenhanced p-polarized reflective coating 36 may be deposited by MSVD.

The enhanced p-polarized reflective coating 36 may be deposited over aportion of or the entire surface of the substrate 42. In some examples,the enhanced p-polarized reflective coating 36 may be deposited over afirst larger region of the substrate 42 and then a portion of the firstlarger region may be “deleted” so that the enhanced p-polarizedreflective coating 36 is positioned over a second smaller region, whichis a sub-region of the first larger region.

1. Base Layer

The base layer 44 may include a nonmetallic layer(s). For example, thebase 44 layer may include dielectric or semiconductor materials. Forexample, the base layer 44 may include oxides, nitrides, oxynitrides,and/or mixtures thereof. Examples of suitable materials for the baselayer 44 may include oxides, nitrides, or oxynitrides of titanium,hafnium, zirconium, niobium, zinc, bismuth, lead, indium, tin, andmixtures thereof. These may have small amounts of other materials, suchas manganese in bismuth oxide, tin in indium oxide, etc. Additionally,oxides of metal alloys or metal mixtures may be used, such as oxidescontaining zinc and tin (e.g., zinc stannate), oxides of indium-tinalloys, silicon nitrides, silicon aluminum nitrides, or aluminumnitrides. Further, doped metal oxides, such as antimony or indium dopedtin oxides or nickel or boron doped silicon oxides, may be used.Particular examples of materials include zinc oxides, tin oxides,silicon nitrides, silicon-aluminum nitrides, silicon-nickel nitrides,silicon-chromium nitrides, antimony doped tin oxide, aluminum doped zincoxide, indium doped zinc oxide, titanium oxide, and/or mixtures thereof.The base layer 44 may include a single material. Alternatively, the baselayer 44 may include multiple materials and/or multiple layers.

The base layer 44 may allow adjustment of the constructive anddestructive optical interference of electromagnetic radiation partiallyreflected from, and/or partially transmitted by, the various interfaceboundaries of the layers of the enhanced p-polarized reflective coating36. Additionally, the base layer 44 may provide chemical and/ormechanical protection for other layers of the enhanced p-polarizedreflective coating 36, such as the metal functional layers 46, 52, 62.

Where high visible light transmittance is desired, the base layer 44 mayact as an antireflective layer to anti-reflect the metal functionallayers 46, 52, 62 to reduce the overall visible light reflectance and/orincrease the visible light transmittance of the enhanced p-polarizedreflective coating 36. Materials having refractive indices around 2 areparticularly useful for anti-reflection of the metal functional layers46, 52, 62.

In the illustrated exemplary enhanced p-polarized reflective coating 36,the base layer 44 may be positioned over at least a portion of thesubstrate 42 (which may be one of the surfaces 24, 26, 30, 32 of one ofthe plies 22, 28). The base layer 44 may be a single layer or mayinclude one or more films of anti-reflective materials and/or dielectricmaterials described above. The base layer 44 may be transparent tovisible light.

As discussed above, the base layer 44 may include a metal oxide, amixture of metal oxides, and/or a metal alloy oxide. For example, thebase layer 44 may include oxides of zinc and tin.

The base layer 44 may have a thickness in the range of 300-550angstroms. For example, the base layer 44 may have a thickness in therange of 300-500 angstroms; 350-430 angstroms or 375-430 angstroms. Forexample, the base layer 44 may have a thickness in the range of 350-550angstroms, 400-500 angstroms; or 420-490 angstroms.

The base layer 44 may include a multi-film structure having a first film66 and/or a second film 68. The first film 66 may be, e.g., a metalalloy oxide film. The second film 68 may be, e.g., a metal oxide film oran oxide mixture film. The second film 68 may be positioned over thefirst film 66.

The first film 66 may be a zinc/tin alloy oxide. By “zinc/tin alloyoxide” is meant both true alloys and also mixtures of the oxides. Thezinc/tin alloy oxide may be that obtained from magnetron sputteringvacuum deposition from a cathode of zinc and tin. The cathode mayinclude zinc and tin in proportions of 5 wt. % to 95 wt. % zinc and 95wt. % to 5 wt. % tin, such as 10 wt. % to 90 wt. % zinc and 90 wt. % to10 wt. % tin. However, other ratios of zinc to tin could also be used.An exemplary metal alloy oxide for the first film 42 may be written asZnxSn_(1-x)O_(2-x) (Formula 1) where “x” varies in the range of greaterthan 0 to less than 1. For instance, “x” may be greater than 0 and maybe any fraction or decimal between greater than 0 to less than 1. Thestoichiometric form of Formula 1 is “Zn₂SnO₄”, commonly referred to aszinc stannate. A zinc stannate layer may be sputter deposited from acathode having 52 wt. % zinc and 48 wt. % tin in the presence of oxygen.For example, the first film 66 may include zinc stannate.

The second film 68 may include a metal oxide film. For example, thesecond film 68 may include zinc oxide. The zinc oxide may be depositedfrom a zinc cathode that includes other materials to improve thesputtering characteristics of the cathode. For example, the zinc cathodemay include a small amount of tin (e.g., up to 10 wt. %, such as up to 5wt. %) to improve sputtering. Thus, the resultant zinc oxide film mayinclude a small percentage of tin oxide, e.g., up to 10 wt. % tin oxide,e.g., up to 5 wt. % tin oxide. A coating layer deposited from a zinccathode having up to 10 wt. % tin is referred to herein as “a zinc oxidefilm” even though a small amount of tin oxide (e.g., up to 10 wt. %) maybe present. The tin in the cathode is believed to form tin oxide in thepredominantly zinc oxide second film 68.

2. Metal Functional Layers

At least one of the metal functional layers 46, 52, 62 may be acontinuous metal layer. By “continuous” metal layer is meant an unbrokenor non-disconnected layer, such as a homogeneous layer.

The metal functional layers 46, 52, 62 provide reflectance ofelectromagnetic radiation in at least a portion of the infraredradiation region of the electromagnetic spectrum, for example, in thesolar infrared radiation region and/or the thermal infrared radiationregion of the electromagnetic spectrum.

Examples of materials useful for the metal functional layers 46, 52, 62include noble or near noble metals. Examples of such metals includesilver, gold, platinum, palladium, osmium, iridium, rhodium, ruthenium,copper, mercury, rhenium, aluminum, and combinations thereof. Forexample, one or more of the metal functional layers 46, 52, 62 mayinclude metallic silver.

The first metal functional layer 46 may be positioned over the baselayer 44 and may include any of the above metals. For example, the firstmetal functional layer 46 may include silver. The first metal functionallayer 46 may be a continuous layer.

The first metal functional layer 46 may be a continuous layer having athickness in the range of 10-200 angstroms. For example, the first metalfunctional layer 46 may have a thickness in the range of 10-200angstroms or 50-150 angstroms. For example, the first metal functionallayer 46 may have a thickness in the range of 10-150 angstroms or 50-125angstroms.

The second metal functional layer 52 may be positioned over the firstphase adjustment layer 50. The second metal functional layer 52 may be acontinuous layer including silver.

The second metal functional layer 52 may be a continuous layer having athickness in the range of 10-150 angstroms. For example, the secondmetal functional layer 52 may have a thickness in the range of 10-150angstroms or 50-125 angstroms. For example, the second metal functionallayer 52 may have a thickness in the range of 10-100 angstroms; 50-75angstroms or 65-75 angstroms.

The third metal functional layer 62 may include any of the materialsdiscussed above with respect to the first or second metal functionallayers 46, 52. For example, the third metal functional layer 62 mayinclude silver. The third metal functional layer 62 may be a continuouslayer positioned over the second phase adjustment layer 60.

For example, the third metal functional layer 62 may be a continuouslayer having a thickness in the range of 50-200 angstroms; 75-150angstroms or 60-140.

The this metal functional layer 46, the second metal functional layer 52and the optional third metal functional layer 62 have a combinedthickness. The combined thickness may be in the range of 100-350angstroms; or 150-300 angstroms or 175-275 angstroms. In embodimentsthat only comprise the first and second metal functional layers 46 and52, the combined thickness may be in the range of 150-250 angstroms,175-225 angstroms; 175-215 angstroms; or 178-211 angstroms. Forembodiments that comprise the first, second and third metal functionallayers 46, 52, and 62, the combine thickness may be in the range of225-325 angstroms, 240-300 angstroms, 250-280 angstroms, or 253-275angstroms.

3. Sacrificial Metal Layers

The sacrificial metal layers 48, 54, 64 may be positioned in directcontact with the associated underlying metal functional layer 46, 52,62. The sacrificial metal layers 48, 54, 64 may protect the associatedmetal functional layers 46, 52, 62 during the coating process and/orsubsequent processing, such as thermal tempering. The sacrificial metallayer 48, 54, 64 may be deposited as a metal. During subsequentprocessing, such as the deposition of the overlying phase adjustmentlayer 50, 60 or topcoat layer 56 and/or thermal tempering, some or allof the sacrificial metal layer 48, 54, 64 may oxidize. When oxide ornitride materials are used in the overlying phase adjustment layer 50,60 or topcoat layer 56, the sacrificial metal layer 48, 54, 64 mayinclude oxophillic or nitrophillic materials, respectively. Thesacrificial metal layers 48, 54, 64 need not be all the same material.The sacrificial metal layers 48, 54, 64 need not be of the samethickness.

Examples of materials useful for the sacrificial metal layers 48, 54, 64include titanium, niobium, tungsten, nickel, chromium, iron, tantalum,zirconium, aluminum, silicon, indium, tin, zinc, molybdenum, hafnium,bismuth, vanadium, manganese, and combinations thereof.

The first sacrificial metal layer 48 may be positioned over the firstmetal functional layer 46. The first sacrificial metal layer 48 may be asingle film or a multiple film layer. The first sacrificial metal layer48 may include any of the materials described above. For example, thefirst sacrificial metal layer 48 may include titanium.

The second sacrificial metal layer 54 may be positioned over the secondmetal functional layer 52. The second sacrificial metal layer 54 may beof any of the materials as described above with respect to the firstsacrificial metal layer 48. For example, the second sacrificial metallayer 54 may include titanium.

The third sacrificial metal layer 64 may be positioned over the thirdmetal functional layer 62. The third sacrificial metal layer 64 may beof any of the materials as described above with respect to the first orsecond sacrificial metal layer 48, 54. For example, the thirdsacrificial metal layer 64 may include titanium.

The sacrificial metal layers 48, 54, 64 may have the same or a differentthickness in the range of 10-50 angstroms, such as 20-40 angstroms or25-35 angstroms. The thickness of the sacrificial metal layers may bechosen to provide sufficient protection to the underlying functionalmetal layer (e.g., such that the sacrificial metals preferably oxidizeto protect the underlying metal functional layer during deposition ofoverlaying layers).

4. Phase Adjustment Layers

The phase adjustment layers 50, 60 may be nonmetallic layers. Forexample, the phase adjustment layers 50, 60 may include dielectric orsemiconductor materials. For example, the phase adjustment layers 50, 60may include oxides, nitrides, oxynitrides, and/or mixtures thereof.Examples of suitable materials for the phase adjustment layers 50, 60may include oxides, nitrides, or oxynitrides of titanium, hafnium,zirconium, niobium, zinc, bismuth, lead, indium, tin, and mixturesthereof. These may have small amounts of other materials, such asmanganese in bismuth oxide, tin in indium oxide, etc. Additionally,oxides of metal alloys or metal mixtures may be used, such as oxidescontaining zinc and tin (e.g., zinc stannate), oxides of indium-tinalloys, silicon nitrides, silicon aluminum nitrides, or aluminumnitrides. Further, doped metal oxides, such as antimony or indium dopedtin oxides or nickel or boron doped silicon oxides, may be used.Particular examples of materials include zinc oxides, tin oxides,silicon nitrides, silicon-aluminum nitrides, silicon-nickel nitrides,silicon-chromium nitrides, antimony doped tin oxide, aluminum doped zincoxide, indium doped zinc oxide, titanium oxide, and/or mixtures thereof.

The phase adjustment layers 50, 60 may include a single material.Alternatively, the phase adjustment layers 50, 60 may include multiplematerials and/or multiple layers. The different phase adjustment layers50, 60 may include the same or different materials. The phase adjustmentlayers 50, 60 may have the same or different thicknesses.

The phase adjustment layers 50, 60 may allow adjustment of theconstructive and destructive optical interference of electromagneticradiation partially reflected from, and/or partially transmitted by, thevarious interface boundaries of the layers of the enhanced p-polarizedreflective coating 36. Varying the thicknesses and/or compositions ofthe phase adjustment layers 50, 60 may change the overall reflectance,transmittance, and/or absorptance of the enhanced p-polarized reflectivecoating 36, which may alter the solar control performance, thermalinfrared insulating performance, color, and/or aesthetics of theenhanced p-polarized reflective coating 36. Additionally, the phaseadjustment layers 50, 60 may provide chemical and/or mechanicalprotection for other layers of the enhanced p-polarized reflectivecoating 36, such as the metal functional layers 46, 52, 62.

Where high visible light transmittance is desired, the phase adjustmentlayers 50, 60 may act as anti-reflective layers to anti-reflect themetal functional layers 46, 52, 62 to reduce the overall visible lightreflectance and/or increase the visible light transmittance of theenhanced p-polarized reflective coating 36. Materials having refractiveindices around 2 are particularly useful for anti-reflection of themetal functional layers 46, 52, 62.

The first phase adjustment layer 50 may be positioned over the firstsacrificial metal layer 48. The first phase adjustment layer 50 mayinclude one or more of the materials and/or films described above.

The first phase adjustment layer 50 may have a thickness in the range of600-1,100 angstroms. For example, the first phase adjustment layer 50may have a thickness in the range of 700-1,100 angstroms, such as850-1,050 angstroms, such as 675-1050 angstroms or such as 689-1048angstroms. For example, the first phase adjustment layer 50 may have athickness in the range of 600-1,000 angstroms, such as 675-875angstroms, or such as 689-866 angstroms. For example, the first phaseadjustment layer 50 may have a thickness in the range of 825-1100angstroms, such as 850-1075 angstroms, such as 875-1050 angstroms, suchas 879-1048 angstroms.

The first phase adjustment layer 50 may be a single layer or amultilayer structure. For example, the first phase adjustment layer 50may include a first film 70, a second film 72, and a third film 74.

For example, the first film 70 may include a metal oxide film. Forexample, the first film 70 may include a zinc oxide film.

For example, the second film 72 may include a metal alloy oxide film.For example, the second film 72 may include a zinc stannate film.

For example, the third film 74 may include a metal oxide film. Forexample, the third film 56 may include a zinc oxide film.

An optional second phase adjustment layer 60 may be positioned over thesecond sacrificial metal layer 54. The second phase adjustment layer 60may include any of the materials and/or layers as discussed above withrespect to the first phase adjustment layers 50. For example, the secondphase adjustment layer 60 may be a multi-film structure. For example,the second phase adjustment layer 60 may include a first film 80, asecond film 82, and a third film 84.

The second phase adjustment layer 60 may have a thickness in the rangeof 500-1,000 angstroms, such as 600-825 angstroms or such as 619-817angstroms.

The first film 80 may include a metal oxide layer, for example, a zincoxide layer. The second film 82 may include a metal alloy oxidematerial, for example, zinc stannate. The third film 84 may include ametal oxide layer, for example, a zinc oxide layer.

5. Topcoat Layer

The topcoat layer 56 may include one or more materials and/or layers asdiscussed above with respect to the first or second phase adjustmentlayers 50, 60.

The topcoat layer 56 may have a thickness in the range of 300-450angstroms. The topcoat layer 56 may have a thickness in the range of300-400 angstroms or 340-375 angstroms. The topcoat layer 56 may have athickness in the range of 275-450 angstroms or 300-415 angstroms or311-411 angstroms or 346-368 angstroms.

The topcoat layer 56 may include a first film 76 and a second film 78.The first film 76 may include a metal oxide layer, for example, a zincoxide layer. The second film 78 may include a metal-alloy oxide layer,for example, a zinc stannate layer.

6. Overcoat

The enhanced p-polarized reflective coating 36 may include an overcoat58 positioned over the topcoat layer 56. The overcoat 58 may bedeposited over the topcoat layer 56 to assist in protecting theunderlying layers from mechanical and chemical attack during processing.The overcoat 58 may be an oxygen barrier coating layer to prevent orreduce the passage of ambient oxygen into the underlying layers of theenhanced p-polarized reflective 36, such as during heating or bending.The overcoat 58 may be of any desired material or mixture of materials.In one exemplary embodiment, the overcoat 58 may include a layer havingone or more metal oxide materials, such as but not limited to oxides ofaluminum, silicon, or mixtures thereof (e.g., be a silica and aluminacoating). For example, the overcoat 58 may be a single coating layerincluding in the range of 0 wt. % to 100 wt. % alumina and/or 100 wt. %to 0 wt. % silica, such as 5 wt. % to 95 wt. % alumina and 95 wt. % to 5wt. % silica, such as 10 wt. % to 90 wt. % alumina and 90 wt. % to 10wt. % silica, such as 15 wt. % to 90 wt. % alumina and 85 wt. % to 10wt. % silica, such as 50 wt. % to 75 wt. % alumina and 50 wt. % to 25wt. % silica, such as 50 wt. % to 70 wt. % alumina and 50 wt. % to 30wt. % silica, such as 35 wt. % to 100 wt. % alumina and 65 wt. % to 0wt. % silica, e.g., 70 wt. % to 90 wt. % alumina and 30 wt. % to 10 wt.% silica, e.g., 75 wt. % to 85 wt. % alumina and 25 wt. % to 15 wt. % ofsilica, e.g., 88 wt. % alumina and 12 wt. % silica, e.g., 65 wt. % to 75wt. % alumina and 35 wt. % to 25 wt. % silica, e.g., 70 wt. % aluminaand 30 wt. % silica, e.g., 60 wt. % to less than 75 wt. % alumina andgreater than 25 wt. % to 40 wt. % silica. The overcoat 58 may be asingle coating layer including 85 wt. % silica and 15 wt. % alumina.Other materials, such as aluminum, chromium, hafnium, yttrium, nickel,boron, phosphorous, titanium, zirconium, and/or oxides thereof, may alsobe present, such as to adjust the refractive index of the overcoat 58.In one non-limiting example, the refractive index of the overcoat 58 maybe in the range of 1 to 3, such as 1 to 2, or such as 1.4 to 2, such as1.4 to 1.8.

The overcoat 58 may be a combination silica and alumina coating. Theovercoat 58 may be sputtered from two cathodes (e.g., one silicon andone aluminum) or from a single cathode containing both silicon andaluminum. This silicon/aluminum oxide overcoat 58 may be written asSixAl_(1-x)O_(1.5+x/2), where “x” may vary from greater than 0 to lessthan 1.

Alternatively, the overcoat 58 may be a multi-layer coating formed byseparately formed layers of metal oxide materials, such as, but notlimited to, a bilayer formed by one metal oxide-containing layer (e.g.,a silica and/or alumina-containing first layer) formed over anothermetal oxide-containing layer (e.g., a silica and/or alumina-containingsecond layer). The individual layers of the multi-layer protectivecoating may be of any desired thickness.

The overcoat 58 may be of any desired thickness. In one non-limitingembodiment, the overcoat 58 may be a silicon/aluminum oxide coating(Si_(x)Al_(1-x)O_(1.5+x/2)) having a thickness in the range of 100-1,000angstroms, such as 600-800 angstroms, or such as 700 angstroms.

Interlayer

Referring to FIGS. 5A and 5B, the laminate 12 may include the interlayer34. The interlayer 34 may be of a suitable material so as to hold theplies 22, 28 together. The

interlayer 34 may be made of a polymer, such as polyvinyl butyral (PVB).The interlayer 34 may be positioned over the second surface 26 and/orthe third surface 30. The interlayer 34 may be in contact with theenhanced p-polarized reflective coating 36. The interlayer 34 may be ofany suitable thickness to hold the plies 22, 28 together. The interlayer34 may be a 0.76 mm thick interlayer 34 of PVB.

Referring to FIG. 5A, the first ply 22 may be non-parallel relative tothe second ply 28. The interlayer 34 may be positioned between the firstply 22 and the second ply 28 and may be wedge-shaped. The wedge-shape ofthe interlayer 34 may be configured such that the radiation 16 reflectsoff of the laminate 12 at the proper angle to avoid ghosting (e.g., toavoid seeing multiple images based on the direction of the lightreflecting off of the laminate 12 converging at different points).

Referring to FIG. 5B, the interlayer 34 may be a layer of uniformthickness in other arrangements of the laminate 12, as the interlayer 34may not need to be wedge-shaped to avoid the ghosting issue becauseother aspects of the design of the laminate 12 counteract ghosting.

Additional Coating Layers

As previously discussed, the laminate 12 may include additional layersbeyond the enhanced p-polarized reflective coating 36. The laminate 12may include the anti-reflective coating 38. The anti-reflective coating38 may be positioned over the first surface 24 and/or the fourth surface32. The anti-reflective coating can comprise alternating layers ofrelatively high and low index of refraction materials. A “high” index ofrefraction material is any material having a higher index of refractionthan that of the “low” index material. The low index of refractionmaterial can be a material having an index of refraction of less than orequal to 1.75. Non-limiting examples of such materials include silica,alumina, and mixtures or combinations thereof. The high index ofrefraction material is a material having an index of refraction ofgreater than 1.75. Non-limiting examples of such materials includezirconia and zinc stannate. The anti-reflective coating can be, forexample, a multi-layer coating having a first metal alloy oxide layer(first layer), a second metal oxide layer (second layer), a third metalalloy oxide layer (third layer), and a metal oxide top layer (fourthlayer). In one non-limiting example, the fourth layer (upper low indexlayer) comprises silica or alumina or a mixture or combination thereof,the third layer (upper high index layer) comprises zinc stannate orzirconia or mixtures or combinations thereof, the second layer (bottomlow index layer) comprises silica or alumina or a mixture or combinationthereof, and the first layer (bottom high index layer) comprises zincstannate or zirconia or mixtures or combinations thereof. Other suitableanti-reflective coatings are disclosed in U.S. Pat. No. 6,265,076 atcolumn 2, line 53 to column 3, line 38; and Examples 1-3. Furthersuitable anti-reflective coatings are disclosed in U.S. Pat. No.6,570,709 at column 2, line 64 to column 5, line 22; column 8, lines12-30; column 10, line 65 to column 11, line 11; column 13, line 7 tocolumn 14, line 46; column 16, lines 35-48; column 19, line 62 to column21, line 4; Examples 1-13; and Tables 1-8.

The anti-reflective coating 38 may reduce the overall visible lightreflectance and/or increase the visible light transmittance of theenhanced p-polarized reflective coating 36. Materials having refractiveindices around 2 are particularly useful for the anti-reflective coating38. It will be appreciated that applying an anti-reflective coating 38over the first surface 24 or the fourth surface 32 may alter theBrewster's angle from the Brewster's angle of an air to glass interfaceor glass to air interface to the Brewster's angle of the air toanti-reflective coating material interface or the anti-reflectivecoating material to air interface. In this way, the amount ofp-polarized radiation reflected and refracted may be altered compared tothe case of the air to glass interface or the glass to air interface byincluding the anti-reflective coating 38.

The display system of substrate may only two metal functional layers oronly three metal functional layers. In embodiments with only two metalfunctions layers, the enhanced p-polarized reflective coating can havethe following ranges of thicknesses for each layer.

More Most Thickness Preferred preferred preferred Layer (Å) (Å) (Å) (Å)Base layer 300-450 350-450 375-430 383-427 1^(st) Metal  10-200  50-175 60-150  66-142 1^(st) Phase Adjustment  700-1100  850-1075  875-1050 879-1048 2^(nd) Metal  10-200  25-175  50-150  65-124 Topcoat 300-400325-375 340-370 346-368 Overcoat  100-1000 500-900 600-800 650-750 Totalthickness 2000-3500 2250-3000 2500-2700 2536-2691 Total metal thickness100-300 125-275 175-225 178-211 Total phase adjustment  750-1250 800-1100  875-1050  879-1048 thickness Total base and phase 1100-16001200-1500 1250-1475 1262-1454 adjustment thickness Total phaseadjustment 1100-1600 1200-1500 1225-1425 1242-1407 and topcoat thicknessTotal phase adjustment, 1250-2000 1500-1900 1600-1850 1625-1813 base andtopcoat thickness

In embodiments with only two metal functions layers, the enhancedp-polarized reflective coating can have the following ranges ofthicknesses for each layer.

More Most Thickness Preferred preferred preferred Layer (Å) (Å) (Å) (Å)Base layer 350-550 400-500 420-490 422-487 1^(st) Metal  10-200  50-150 50-125  65-123 1^(st) Phase Adjustment  600-1100 650-950 675-875689-866 2^(nd) Metal  10-150  50-125 65-75 67-74 2^(nd) Phase Adjustment 500-1000 550-900 600-825 619-817 3^(rd) Metal  50-200  55-175  60-150 65-135 Topcoat 300-400 375-450 300-425 311-411 Overcoat  100-1000500-900 600-800 650-750 Total thickness 3000-3750 3100-3500 3200-34003236-3372 Total metal thickness 175-375 200-350 250-275 253-275 Totalphase adjustment 1200-1800 1300-1700 1450-1575 1485-1567 thickness Totalbase and phase 1700-2250 1725-2175 1900-2025 1924-2016 adjustmentthickness Total phase adjustment 1500-2250 1600-2100 1775-1950 1796-1943and topcoat thickness Total phase adjustment, 1800-2800 2000-26002250-2400 2283-2397 base and topcoat thickness

Brewster's Angle

The Brewster's angle is defined as an angle of incidence at whichp-polarized radiation is perfectly transmitted through the surface ofthe laminate 12 contacted by the p-polarized radiation. In other words,the Brewster's angle is the angle of incidence at which all p-polarizedradiation is refracted/transmitted such that no p-polarized radiation isreflected.

The Brewster's angle for an air to glass interface (such as when thelaminate 12 is glass) is approximately 57°. The Brewster's angle for aglass to air interface (such as when the laminate 12 is glass) isapproximately 33°. Thus, when the incidence angle of the radiation 16hitting the fourth surface 32 of the laminate 12 from the radiationsource 14 on an inner side of the laminate 12 having an air to glassinterface is 57°, all p-polarized radiation is refracted and none isreflected off of the fourth surface 32 to the eye 20 of the user.

Referring to FIG. 6 , the Brewster's angle of the fourth surface 32 ofthe system 10 may be altered by positioning the enhanced p-polarizedreflective coating 36 over the first surface 24 or the fourth surface32. In FIG. 6 , the enhanced p-polarized reflective coating 36 ispositioned over the fourth surface 32. In this case, the Brewster'sangle at the fourth surface 32 becomes the Brewster's angle for the airto enhanced p-polarized reflective coating 36 interface.

With continued reference to FIG. 6 , ghosting may be eliminated bypositioning the enhanced p-polarized reflective coating 36 on the firstsurface 24 or the fourth surface 32 by adjusting the angle at which theradiation 16 hits the enhanced p-polarized reflective coating 36. Anexample will be explained with the enhanced p-polarized reflectivecoating 36 positioned over the fourth surface 32, as shown in FIG. 6 .The radiation 16 may contact the enhanced p-polarized reflective coating36 at a coating incidence angle θ_(c). This coating incidence angleθ_(c) may be selected such that an incidence angle θ_(b) at the firstsurface 24 is the Brewster's angle for the glass to air interface. Inother words, the coating incidence angle θ_(c) may be selected such thatthe incidence angle θ_(b) is 33°. In this scenario, p-polarizedradiation reflects off of the enhanced p-polarized reflective coating 36at the fourth surface 32 to the eye 20 of the user but does not reflectoff of the first surface 24 to the eye 20 of the user because allp-polarized radiation is refracted through at the Brewster's angle. If apolarized filter 18 is used to filter substantially all s-polarizedradiation prior to reaching the laminate 12, only p-polarized radiationreflected off of the enhanced p-polarized reflective coating 36 at thefourth surface 32 (as shown in FIG. 6 ) reaches the eye 20 of the user,and ghosting is therefore reduced or eliminated. It will be appreciatedthat the enhanced p-polarized reflective coating 36 may be positionedover the first surface 24 and the radiation 16 may be directed at thelaminate 12 such that the radiation 16 contacts the fourth surface 32 atthe Brewster's angle of that air to glass interface (57°) interface andcontacts the first surface 24 at an angle that is not the Brewster'sangle of that glass to enhanced p-polarized reflective coating 36interface.

Test Configuration

Referring to FIG. 7 , a test apparatus 86 for which the radiation 16from the radiation source 14 contacts the laminate 12 at an angle of 60°relative to normal of the laminate 12 is shown. In the test apparatus86, the radiation source 14 is positioned such that the radiation 16emitted therefrom contacts the laminate 12 at an incident angle of 60°relative to normal of the laminate 12. Properties (reference laminatedvalues) of the laminate 12 and the reflected radiation 16 may bemeasured from test apparatus 86.

Using the test apparatus 86, the laminate 12, including thepreviously-described first ply 22, second ply 28, interlayer 34, andenhanced p-polarized reflective coating 36, may exhibit a luminoustransmittance using standard illuminate A (LTA) of at least 70%, asmeasured according automotive industry standards. Using the testapparatus 86, the laminate 12, including the previously-described firstply 22, second ply 28, interlayer 34, and enhanced p-polarizedreflective coating 36, may exhibit a reflectivity of the p-polarizedradiation using D65 illuminate and a 10° detector of at least 10%. Usingthe test apparatus 86, the laminate 12, including thepreviously-described first ply 22, second ply 28, interlayer 34, andenhanced p-polarized reflective coating 36, may have a totalreflectivity of up to 60%, such as up to 55% or up to 52%.

EXAMPLES

The following examples are presented to demonstrate the generalprinciples of the invention. The invention should not be considered aslimited to the specific examples presented.

The following examples show enhanced p-polarized reflective coatingsaccording to the present invention alongside several comparativeexamples. The examples and comparative examples are computer modeledsamples reproducible using commercially available software, such asOPTICS (v.6.0) software and WINDOW (v7.3.4.0) software available fromLawrence Berkeley National Laboratory or WVASE software available fromJ. A. Woollam Co. The enhanced p-polarized reflective coatings weremodeled and values calculated having the coatings applied over a surfaceof a laminate. The laminate was modeled to include two plies of 2 mmclear glass with a 0.76 mm interlayer of polyvinyl butyral (PVB)therebetween. The coating was applied over at least a portion of thethird surface, as previously defined, of the laminate.

Table 1 shows the thicknesses of the various layers of the modeledcoatings (in angstroms). Not shown in Table 1 are the thicknesses of thesacrificial metal layers modeled directly over top of each respectivemetal functional layer. The thickness of each sacrificial metal layerranged between 10-50 angstroms, but any adequate thickness could beselected.

TABLE 1 Comp. Comp. Comp. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex.Ex. Ex. Layer Ex. 1 Ex. 2 Ex. 3 1 2 3 4 5 6 7 8 9 10 11 12 13 Base Layer0 325 419 454 450 422 426 487 442 449 387 406 387 383 427 390 FirstMetal 0 110 110 66 66 68 68 105 65 123 128 112 128 142 66 126 FunctionalLayer First Phase 0 825 684 726 704 689 693 866 721 859 974 1048 974 879990 985 Adjustment Layer Second Metal 0 78 126 74 74 70 68 68 69 67 6666 66 69 124 65 Functional Layer Second 0 0 768 806 793 817 805 619 808708 0 0 0 0 0 0 Phase Adjustment Layer Third Metal 0 0 135 135 132 126125 80 127 65 0 0 0 0 0 0 Functional Layer Topcoat 0 250 383 411 392 408405 311 401 347 368 359 368 363 346 368 Layer Overcoat 0 700 700 700 700700 700 700 700 700 700 700 700 700 700 700

Comparative Example 1 is an uncoated laminate. Comparative Examples 2and 3 are commercially available coatings. Examples 1-7 are triple metalfunctional layer enhanced p-reflective reflective coatings of thepresent invention which have been optimized to have enhanced p-polarizedradiation reflecting properties applied on the laminate. Examples 8-13are double metal functional layer enhanced p-polarized reflectivecoatings of the present invention which have been optimized to haveenhanced p-polarized radiation reflecting properties applied on thelaminate.

From Table 1, for the triple metal functional layer enhanced p-polarizedreflective coatings: the base layer was applied directly over thesubstrate and included a first film directly over the substrate and asecond film directly over the first film. The first film included a zincstannate (Zn₂SnO₄) layer. The second film included a zinc oxide layer(which included up to 10 wt. % tin oxide). The first metal functionallayer was applied directly over the base layer and was a metallic silverlayer. A first sacrificial metal layer was applied directly over thefirst metal functional layer and was a titanium (TiO_(x)) layer. Aspreviously discussed, the sacrificial metal layers were deposited asmetal titanium and all or part of the layer subsequently oxidized duringsubsequent processing steps. The first phase adjustment layer wasapplied directly over the first sacrificial metal layer and included afirst film, a second film, and a third film. The first film was applieddirectly over the first sacrificial metal layer and included a zincoxide layer (which included up to 10 wt. % tin oxide). The second filmwas applied directly over the first film and included a zinc stannatelayer. The third film was applied directly over the second film andincluded a zinc oxide layer (which included up to 10 weight % tinoxide). A second metal functional layer was applied directly over thefirst phase adjustment layer and was a metallic silver layer. A secondsacrificial metal layer was applied directly over the second metalfunctional layer and was a titanium (TiO_(x)) layer (like the firstsacrificial metal layer). A second phase adjustment layer was applieddirectly over the second sacrificial metal layer and included a firstfilm, a second film, and a third film. The first film was applieddirectly over the second sacrificial metal layer and included a zincoxide layer (which included up to 10 wt. % tin oxide). The second filmwas applied directly over the first film and included a zinc stannatelayer. The third film was applied directly over the second film andincluded a zinc oxide layer (which included up to 10 wt. % tin oxide). Athird metal functional layer was applied directly over the second phaseadjustment layer and was a metallic silver layer. A third sacrificialmetal layer was applied directly over the third metal functional layerand was a titanium (TiO_(x)) layer (like the first and secondsacrificial metal layer). A topcoat layer was applied directly over thethird sacrificial metal layer and included a first film and a secondfilm. The first film was applied directly over the third sacrificialmetal layer and included a zinc oxide layer (which included up to 10 wt.% tin oxide). The second film was applied directly over the first filmand included a zinc stannate layer. An overcoat was applied directlyover the topcoat layer and included a combination silica and aluminacoating having 85% SiO₂ and 15% Al₂O₃.

From Table 1, for the double metal functional layer enhanced p-polarizedreflective coatings: the base layer was applied directly over thesubstrate and included a first film directly over the substrate and asecond film directly over the first film. The first film included a zincstannate (Zn₂SnO₄) layer. The second film included a zinc oxide layer(which included up to 10 wt. % tin oxide). The first metal functionallayer was applied directly over the base layer and was a metallic silverlayer. A first sacrificial metal layer was applied directly over thefirst metal functional layer and was a titanium (TiO_(x)) layer. Aspreviously discussed, the sacrificial metal layers were deposited asmetal titanium and all or part of the layer subsequently oxidized duringsubsequent processing steps. The first phase adjustment layer wasapplied directly over the first sacrificial metal layer and included afirst film, a second film, and a third film. The first film was applieddirectly over the first sacrificial metal layer and included a zincoxide layer (which included up to 10 wt. % tin oxide). The second filmwas applied directly over the first film and included a zinc stannatelayer. The third film was applied directly over the second film andincluded a zinc oxide layer (which included up to 10 wt. % tin oxide). Asecond metal functional layer was applied directly over the first phaseadjustment layer and was a metallic silver layer. A second sacrificialmetal layer was applied directly over the second metal functional layerand was a titanium (TiO_(x)) layer (like the first sacrificial metallayer). A topcoat layer was applied directly over the second sacrificialmetal layer and included a first film and a second film. The first filmwas applied directly over the second sacrificial metal layer andincluded a zinc oxide layer (which included up to 10 wt. % tin oxide).The second film was applied directly over the first film and included azinc stannate layer. An overcoat was applied directly over the topcoatlayer and included a combination silica and alumina coating having 85%SiO₂ and 15% Al₂O₃.

Table 2 shows the calculated results of relevant characteristics,reproducible using the previously-described software.

In Table 2, “P-Rf60-Y” means the reflectivity of the p-polarizedradiation using D65 illuminate and a 10° detector from the film side(external side), according to CIE 1964 10° Supplementary StandardObserver. “P-Rg60-Y” means the reflectivity of the p-polarized radiationusing D65 illuminate and a 10° detector from the glass side (internalside), according to CIE 1964 10° Supplementary Standard Observer. “LTA”means luminous transmittance using standard illuminate A (LTA). “RfL*”,“Rfa*”, and “Rfa*” are reflectivity from the film side for color values:L*, a*, b*. L*, a*, and b* which are in accordance with the 1976 CIELABcolor system specified by the International Commission on Illumination.The L*, a*, and b* values represent color center point values. “Tsol”means the solar transmittance of the laminate. “RfSol” means solarreflectance of the laminate from the film side.

TABLE 2 Measured Comp. Comp. Comp. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex.Ex. Ex. Ex. Ex. Value Ex. 1 Ex. 2 Ex. 3 1 2 3 4 5 6 7 8 9 10 11 12 13P-Rf60-Y 0.4 4.69 6.30 12.30 11.27 11.52 11.55 11.15 11.4 10.7 13.0113.05 13.01 12.04 12.85 13.1 P-Rg60-Y — 5.21 6.12 11.29 10.35 10.9110.93 11.52 — — 13.43 13.16 13.43 13.10 12.85 — LTA 88.4 77.63 71.8970.45 71.28 71.23 71.26 71.18 71.5 71.5 71.68 72.35 71.68 71.38 72.3171.7 RfL* 34.1 43.01 40.37 47.61 46.50 46.76 46.61 46.26 46.3 45.6 51.4351.16 51.43 50.34 50.46 51.5 Rfa* −0.8 −9.03 −8.12 −2.77 −3.68 −2.52−2.33 0.13 −2.0 1.5 −2.42 −2.29 −2.42 −1.75 −0.51 −2.2 Rfb* 0.0 −4.50−0.19 3.91 3.60 2.57 4.01 2.91 4.5 −1.3 0.51 1.25 0.51 0.03 −1.22 0.8Tsol 73.3 43.6 31.6 38.4 38.6 39.8 40.1 41.4 40.1 41.3 42.9 46.2 42.939.5 43.9 43.4 RfSol — 28.2 37.2 32.0 31.7 30.3 30.0 27.6 — — 28.6 25.628.6 31.7 29.2 —

The inventive laminates exhibit enhanced p-polarized radiationreflecting properties, such that the reflectivity of the p-polarizedradiation is at least 10%, while maintaining an LTA of at least 70%.

The invention is further described in the following numbered clauses.

Clause 1: A laminate having enhanced p-polarized radiation reflectingproperties comprising: a first ply comprising a first surface and asecond surface opposite the first surface, wherein the first surfacecomprises an outer surface of the laminate; a second ply comprising athird surface adjacent the second surface and a fourth surface oppositethe third surface, wherein the fourth surface comprises an inner surfaceof the laminate; an interlayer positioned between the first ply and thesecond ply; and an enhanced p-polarized reflective coating positionedover at least a portion of at least one of the surfaces of the first plyand/or the second ply, wherein, when contacted with radiation from aradiation source, the radiation comprising p-polarized radiation, at anangle of 60° relative to normal of the laminate, the laminate exhibits aluminous transmittance using standard illuminate A (LTA) value of atleast 70% and a reflectivity of the p-polarized radiation of at least10%.

Clause 2: The laminate of clause 1, wherein the enhanced p-polarizedreflective coating comprises a plurality of layers.

Clause 3: The laminate of clause 1 or 2, wherein the enhancedp-polarized reflective coating is positioned over at least a portion ofthe second surface or the third surface.

Clause 4: The laminate of clause 2 or 3, wherein the enhancedp-polarized reflective coating comprises: a base layer positioned overthe portion of the at least one of the surfaces; a first metalfunctional layer positioned over at least a portion of the base layer;an optional first sacrificial metal layer positioned over at least aportion of the first metal functional layer; a first phase adjustmentlayer positioned over at least a portion of the first sacrificial metallayer; a second metal functional layer positioned over at least aportion of the first phase adjustment layer; a second sacrificial metallayer positioned over at least a portion of the second metal functionallayer; a topcoat layer positioned over at least a portion of the secondsacrificial metal layer; and an overcoat positioned over at least aportion of the topcoat layer.

Clause 5: The laminate of clause 4, wherein the enhanced p-polarizedreflective coating further comprises: a second phase adjustment layerpositioned over at least a portion of the second sacrificial metallayer; a third metal functional layer positioned over at least a portionof the second phase adjustment layer; a third sacrificial metal layerpositioned over at least a portion of the third metal functional layer;the topcoat layer positioned over at least a portion of the thirdsacrificial metal layer; and the overcoat positioned over at least aportion of the topcoat layer.

Clause 6: The laminate of clause 4 or 5, wherein the base layercomprises: a first film comprising a metal alloy oxide film; and asecond film positioned over the first film of the base layer, the secondfilm of the base layer comprising an oxide mixture film.

Clause 7: The laminate of clause 6, wherein the first film of the baselayer comprises a zinc/tin alloy oxide, preferably zinc stannate.

Clause 8: The laminate of clause 6 or 7, wherein the second film of thebase layer comprises a metal oxide film, preferably zinc oxide.

Clause 9: The laminate of any of clauses 4-8, wherein the first phaseadjustment layer and/or the second phase adjustment layer comprises: afirst film comprising a metal oxide film; a second film positioned overthe first film of the first phase adjustment layer and/or the secondphase adjustment layer, the second film of the first phase adjustmentlayer and/or the second phase adjustment layer comprising a metal-alloyoxide film; and a third film positioned over the second film of thefirst phase adjustment layer and/or the second phase adjustment layer,the third film of the first phase adjustment layer and/or the secondphase adjustment layer comprising a metal oxide film.

Clause 10: The laminate of clause 9, wherein the first film of the firstphase adjustment layer and/or the second phase adjustment layer and/orthe third film of the first phase adjustment layer and/or the secondphase adjustment layer comprises a metal oxide film, preferably zincoxide.

Clause 11: The laminate of clause 9 or 10, wherein the second film ofthe first phase adjustment layer and/or the second phase adjustmentlayer comprises a zinc/tin alloy oxide, preferably zinc stannate.

Clause 12: The laminate of any of clauses 4-11, wherein the first metalfunctional layer, the second metal functional layer, and/or the thirdmetal functional layer comprises at least one noble or near noble metal,particularly selected from silver, gold, platinum, palladium, osmium,iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, andcombinations thereof, more preferably metallic silver.

Clause 13: The laminate of any of clauses 4-12, wherein the first metalfunctional layer, the second metal functional layer, and/or the thirdmetal functional layer comprises metallic silver.

Clause 14: The laminate of any of clauses 4-13, wherein the firstsacrificial metal layer, the second sacrificial metal layer, and/or thethird sacrificial metal layer comprises at least one of titanium,niobium, tungsten, nickel, chromium, iron, tantalum, zirconium,aluminum, silicon, indium, tin, zinc, molybdenum, hafnium, bismuth,vanadium, manganese, and combinations thereof, preferably titanium.

Clause 15: The laminate of any of clauses 4-14, wherein the firstsacrificial metal layer, the second sacrificial metal layer, and/or thethird sacrificial metal layer has a thickness in the range of 10-50angstroms, preferably 20-40 angstroms, more preferably 25-35 angstroms.

Clause 16: The laminate of any of clauses 4-15, wherein the topcoatlayer comprises: a first film comprising a metal oxide film; and asecond film positioned over the first film of the topcoat layer, thesecond film of the topcoat layer comprising a metal-alloy oxide film.

Clause 17: The laminate of clause 16, wherein the second film of thetopcoat layer comprises a zinc/tin alloy oxide, preferably zincstannate.

Clause 18: The laminate of clause 16 or 17, wherein the first film ofthe topcoat layer comprises a metal oxide film, preferably zinc oxide.

Clause 19: The laminate of any of clauses 4-18, wherein the overcoatcomprises a combination silica and alumina coating.

Clause 20: The laminate of any of clauses 2-19, further comprising ananti-reflective coating positioned over at least a portion of the firstsurface or the fourth surface.

Clause 21: The laminate of clause 20, wherein the anti-reflectivecoating comprises a multi-layer coating having a first metal alloy oxidelayer (first layer), a second metal oxide layer (second layer), a thirdmetal alloy oxide layer (third layer), and a metal oxide top layer(fourth layer).

Clause 22: The laminate of any of clauses 1-21, wherein the enhancedp-polarized reflective coating is positioned over at least a portion ofthe first surface or the fourth surface.

Clause 23: The laminate of any of clauses 1-22, wherein the first plyand the second ply are non-parallel relative to one another.

Clause 24: The laminate of any of clauses 1-23, wherein the interlayercomprises a wedge-shaped interlayer.

Clause 25: The laminate of any of clauses 1-24, wherein the interlayercomprises a coating layer of uniform thickness.

Clause 26: The laminate of any of clauses 1-25, wherein the interlayercomprises polyvinyl butyral (PVB).

Clause 27: The laminate of any of clauses 1-26, wherein, when contactedwith the radiation from the radiation source at an angle of 60° relativeto normal of the laminate, the laminate exhibits a total reflectivity ofup to 60%, preferably up to 55%, more preferably up to 52%.

Clause 28: The laminate of any of clauses 1-27, wherein the laminatecomprises an automotive laminate.

Clause 29: A display system for projecting an image comprising: alaminate having enhanced p-polarized radiation reflecting propertiescomprising: a first ply comprising a first surface and a second surfaceopposite the first surface, wherein the first surface comprises an outersurface of the laminate; a second ply comprising a third surfaceadjacent the second surface and a fourth surface opposite the thirdsurface, wherein the fourth surface comprises an inner surface of thelaminate; an interlayer positioned between the first ply and the secondply; and an enhanced p-polarized reflective coating positioned over atleast a portion of at least one of the surfaces of the first ply and/orthe second ply, wherein, when contacted with radiation from a radiationsource, the radiation comprising p-polarized radiation at an angle of60° relative to normal of the laminate, the laminate exhibits a luminoustransmittance using standard illuminate A (LTA) value of at least 70%and a reflectance of the p-polarized radiation of at least 10%; and aradiation source directed at the laminate, the radiation source emittingradiation comprising p-polarized radiation.

Clause 30: The system of clause 29, further comprising a polarizedfilter positioned between the light source and the laminate andconfigured to allow at least a portion of the p-polarized radiation topass therethrough.

Clause 31: The system of clause 30, wherein the polarized filter filtersat least a portion of s-polarized radiation emitted from the radiationsource.

Clause 32: The system of clause 31, wherein the polarized filter filterssubstantially all of the s-polarized radiation emitted from theradiation source.

Clause 33: The system of any of clauses 29-32, wherein, when theradiation source emits the radiation directed at the laminate, an imageis projected to an area of an inner side of the laminate.

Clause 34: The system of clause 33, wherein the image is at least oneof:

-   -   a static image or a dynamic image.

Clause 35: The system of clause 33 or 34, wherein the image comprises acolor.

Clause 36: The system of any of clauses 29-35, wherein the imagecomprises an image in a heads-up display.

Clause 37: The system of any of clauses 29-36, wherein the laminatecomprises an automotive laminate.

Clause 38: The system of any of clauses 29-37, wherein the enhancedp-polarized reflective coating is positioned over at least a portion ofthe second surface or the third surface.

Clause 39: The system of clause 38, wherein the enhanced p-polarizedreflective coating is positioned over at least a portion of the firstsurface or the fourth surface.

Clause 40: The system of clause 39, wherein the enhanced p-polarizedreflective coating is positioned over at least a portion of the fourthsurface and the radiation source directed at the laminate is positionedat an angle relative to the laminate such that the radiation contactsthe first surface at an angle substantially equal to a Brewster's anglefor a first surface to air interface, or the enhanced p-polarizedreflective coating is positioned over at least a portion of the firstsurface and the radiation source directed at the laminate is positionedat an angle relative to the laminate such that the radiation contactsthe fourth surface at an angle substantially equal to a Brewster's anglefor an air to fourth surface interface.

Clause 41: The system of any of the clauses 29-40, wherein the enhancedp-polarized reflective coating comprises: a base layer positioned overthe portion of the at least one of the surfaces; a first metalfunctional layer positioned over at least a portion of the base layer;an optional first sacrificial metal layer positioned over at least aportion of the first metal functional layer; a first phase adjustmentlayer positioned over at least a portion of the first sacrificial metallayer; a second metal functional layer positioned over at least aportion of the first phase adjustment layer; a second sacrificial metallayer positioned over at least a portion of the second metal functionallayer; a topcoat layer positioned over at least a portion of the secondsacrificial metal layer; and an overcoat positioned over at least aportion of the topcoat layer.

Clause 42: The system of clause 41, wherein the enhanced p-polarizedreflective coating further comprises: a second phase adjustment layerpositioned over at least a portion of the second sacrificial metallayer; a third metal functional layer positioned over at least a portionof the second phase adjustment layer; a third sacrificial metal layerpositioned over at least a portion of the third metal functional layer;the topcoat layer positioned over at least a portion of the thirdsacrificial metal layer; and the overcoat positioned over at least aportion of the topcoat layer.

Clause 43: The system of clause 41 or 42, wherein the base layercomprises: a first film comprising a metal alloy oxide film; and asecond film positioned over the first film of the base layer, the secondfilm of the base layer comprising an oxide mixture film.

Clause 44: The system of clause 43, wherein the first film of the baselayer comprises a zinc/tin alloy oxide, preferably zinc stannate.

Clause 45: The system of clause 43 or 44, wherein the second film of thebase layer comprises a metal oxide film, preferably zinc oxide.

Clause 46: The system of any of clauses 41-45, wherein the first phaseadjustment layer and/or the second phase adjustment layer comprises: afirst film comprising a metal oxide film; a second film positioned overthe first film of the first phase adjustment layer and/or the secondphase adjustment layer, the second film of the first phase adjustmentlayer and/or the second phase adjustment layer comprising a metal-alloyoxide film; and a third film positioned over the second film of thefirst phase adjustment layer and/or the second phase adjustment layer,the third film of the first phase adjustment layer and/or the secondphase adjustment layer comprising a metal oxide film.

Clause 47: The system of clause 46, wherein the first film of the firstphase adjustment layer and/or the second phase adjustment layer and/orthe third film of the first phase adjustment layer and/or the secondphase adjustment layer comprises a metal oxide film, preferably zincoxide.

Clause 48: The system of clause 46 or 47, wherein the second film of thefirst phase adjustment layer and/or the second phase adjustment layercomprises a zinc/tin alloy oxide, preferably zinc stannate.

Clause 49: The system of any of clauses 41-48, wherein the first metalfunctional layer, the second metal functional layer, and/or the thirdmetal functional layer comprises at least one noble or near noble metal,particularly selected from silver, gold, platinum, palladium, osmium,iridium, rhodium, ruthenium, copper, mercury, rhenium, aluminum, andcombinations thereof, more preferably metallic silver.

Clause 50: The system of any of clauses 41-49, wherein the first metalfunctional layer, the second metal functional layer, and/or the thirdmetal functional layer comprises metallic silver.

Clause 51: The system of any of clauses 41-50, wherein the firstsacrificial metal layer, the second sacrificial metal layer, and/or thethird sacrificial metal layer comprises at least one of titanium,niobium, tungsten, nickel, chromium, iron, tantalum, zirconium,aluminum, silicon, indium, tin, zinc, molybdenum, hafnium, bismuth,vanadium, manganese, and combinations thereof, preferably titanium.

Clause 52: The system of any of clauses 41-51, wherein the firstsacrificial metal layer, the second sacrificial metal layer, and/or thethird sacrificial metal layer has a thickness in the range of 10-50angstroms, preferably 20-40 angstroms, more preferably 25-35 angstroms.

Clause 53: The system of any of clauses 41-52, wherein the topcoat layercomprises: a first film comprising a metal oxide film; and a second filmpositioned over the first film of the topcoat layer, the second film ofthe topcoat layer comprising a metal-alloy oxide film.

Clause 54: The system of clause 53, wherein the second film of thetopcoat layer comprises a zinc/tin alloy oxide, preferably zincstannate.

Clause 55: The system of clause 53 or 54, wherein the first film of thetopcoat layer comprises a metal oxide film, preferably zinc oxide.

Clause 56: The system of any of clauses 41-55, wherein the overcoatcomprises a combination silica and alumina coating.

Clause 57: The system of any of clauses 29-56, further comprising ananti-reflective coating positioned over at least a portion of the firstsurface or the fourth surface.

Clause 58: The system of clause 57, wherein the anti-reflective coatingcomprises a multi-layer coating having a first metal alloy oxide layer(first layer), a second metal oxide layer (second layer), a third metalalloy oxide layer (third layer), and a metal oxide top layer (fourthlayer).

Clause 59: The system of any of clauses 29-58, wherein the enhancedp-polarized reflective coating is positioned over at least a portion ofthe first surface or the fourth surface.

Clause 60: The system of any of clauses 29-59, wherein the first ply andthe second ply are non-parallel relative to one another.

Clause 61: The system of any of clauses 29-60, wherein the interlayercomprises a wedge-shaped interlayer.

Clause 62: The system of any of clauses 29-61, wherein the interlayercomprises a coating layer of uniform thickness.

Clause 63: The system of any of clauses 29-62, wherein the interlayercomprises polyvinyl butyral (PVB).

Clause 64: The system of any of clauses 29-63, wherein, when contactedwith the radiation from the radiation source at an angle of 60° relativeto normal of the laminate, the laminate exhibits a total reflectivity ofup to 60%, preferably up to 55%, more preferably up to 52%.

Clause 65: The system of any of clauses 29-64, wherein the laminatecomprises an automotive laminate.

Clause 66: A method of projecting an image in a heads-up displaycomprising: providing a laminate having enhanced p-polarized radiationreflecting properties comprising: a first ply comprising a first surfaceand a second surface opposite the first surface, wherein the firstsurface comprises an outer surface of the laminate; a second plycomprising a third surface adjacent the second surface and a fourthsurface opposite the third surface, wherein the fourth surface comprisesan inner surface of the laminate; an interlayer positioned between thefirst ply and the second ply; and an enhanced p-polarized reflectivecoating positioned over at least a portion of at least one of thesurfaces of the first ply and/or the second ply, wherein, when contactedwith radiation from a radiation source, the radiation comprisingp-polarized radiation at an angle of 60° relative to normal of thelaminate, the laminate exhibits a luminous transmittance using standardilluminate A (LTA) value of at least 70% and a reflectivity of thep-polarized radiation of at least 10%; and directing the radiationsource emitting the radiation comprising p-polarized radiation at thelaminate, such that an image is projected to an area of an inner side ofthe laminate.

Clause 67: A laminate having enhanced p-polarized radiation reflectingproperties comprising: a first ply comprising a first surface and asecond surface opposite the first surface, wherein the first surfacecomprises an outer surface of the laminate; a second ply comprising athird surface adjacent the second surface and a fourth surface oppositethe third surface, wherein the fourth surface comprises an inner surfaceof the laminate; an interlayer positioned between the first ply and thesecond ply; and an enhanced p-polarized reflective coating positionedover at least a portion of at least one of the surfaces of the first plyand/or the second ply, wherein, when contacted with radiation from aradiation source, the radiation comprising p-polarized radiation, at anangle of 60° relative to normal of the laminate, the laminate exhibits aluminous transmittance using standard illuminate A (LTA) value of atleast 70% and a reflectivity of the p-polarized radiation of at least5%.

Clause 68: A laminate having enhanced p-polarized radiation reflectingproperties comprising: a first ply comprising a first surface and asecond surface opposite the first surface, wherein the first surfacecomprises an outer surface of the laminate; a second ply comprising athird surface adjacent the second surface and a fourth surface oppositethe third surface, wherein the fourth surface comprises an inner surfaceof the laminate; an interlayer positioned between the first ply and thesecond ply; and an enhanced p-polarized reflective coating positionedover at least a portion of at least one of the surfaces of the first plyand/or the second ply, wherein, when contacted with radiation from aradiation source, the radiation comprising p-polarized radiation, at anangle of 60° relative to normal of the laminate, the laminate exhibits aluminous transmittance using standard illuminate A (LTA) value of atleast 70% and a reflectivity of the p-polarized radiation of at least5%, with Rfa* in the range of −2 to 2 and Rfb* in the range of −2 to 2.

Clause 69: A laminate having enhanced p-polarized radiation reflectingproperties comprising: a first ply comprising a first surface and asecond surface opposite the first surface, wherein the first surfacecomprises an outer surface of the laminate; a second ply comprising athird surface adjacent the second surface and a fourth surface oppositethe third surface, wherein the fourth surface comprises an inner surfaceof the laminate; an interlayer positioned between the first ply and thesecond ply; and an enhanced p-polarized reflective coating positionedover at least a portion of at least one of the surfaces of the first plyand/or the second ply, wherein, when contacted with radiation from aradiation source, the radiation comprising p-polarized radiation, at anangle of 60° relative to normal of the laminate, the laminate exhibits aluminous transmittance using standard illuminate A (LTA) value of atleast 70% and a reflectivity of the p-polarized radiation of at least5%, with Rfa* in the range of −2 to 2.

Clause 70: A laminate having enhanced p-polarized radiation reflectingproperties comprising: a first ply comprising a first surface and asecond surface opposite the first surface, wherein the first surfacecomprises an outer surface of the laminate; a second ply comprising athird surface adjacent the second surface and a fourth surface oppositethe third surface, wherein the fourth surface comprises an inner surfaceof the laminate; an interlayer positioned between the first ply and thesecond ply; and an enhanced p-polarized reflective coating positionedover at least a portion of at least one of the surfaces of the first plyand/or the second ply, wherein, when contacted with radiation from aradiation source, the radiation comprising p-polarized radiation, at anangle of 60° relative to normal of the laminate, the laminate exhibits aluminous transmittance using standard illuminate A (LTA) value of atleast 70% and a reflectivity of the p-polarized radiation of at least5%, with Rfb* in the range of −2 to 2.

Clause 71: A laminate having enhanced p-polarized radiation reflectingproperties comprising: a first ply comprising a first surface and asecond surface opposite the first surface, wherein the first surfacecomprises an outer surface of the laminate; a second ply comprising athird surface adjacent the second surface and a fourth surface oppositethe third surface, wherein the fourth surface comprises an inner surfaceof the laminate; an interlayer positioned between the first ply and thesecond ply; and an enhanced p-polarized reflective coating positionedover at least a portion of at least one of the surfaces of the first plyand/or the second ply, wherein, when contacted with radiation from aradiation source, the radiation comprising p-polarized radiation, at anangle of 60° relative to normal of the laminate, the laminate exhibits aluminous transmittance using standard illuminate A (LTA) value of atleast 70% and a reflectivity of the p-polarized radiation of at least5%, with exterior reflectance less than or equal to 15%.

Although the invention has been described in detail for the purpose ofillustration based on what is currently considered to be the mostpractical and preferred embodiments, it is to be understood that suchdetail is solely for that purpose and that the invention is not limitedto the disclosed embodiments, but, on the contrary, is intended to covermodifications and equivalent arrangements that are within the spirit andscope of the appended claims. For example, it is to be understood thatthe present invention contemplates that, to the extent possible, one ormore features of any embodiment can be combined with one or morefeatures of any other embodiment.

The invention claimed is:
 1. A laminate having enhanced p-polarizedradiation reflecting properties comprising: a first ply comprising afirst surface and a second surface opposite the first surface, whereinthe first surface comprises an outer surface of the laminate; a secondply comprising a third surface adjacent the second surface and a fourthsurface opposite the third surface, wherein the fourth surface comprisesan inner surface of the laminate; an interlayer positioned between thefirst ply and the second ply; and an enhanced p-polarized reflectivecoating positioned over at least a portion of at least one of thesurfaces of the first ply and/or the second ply, wherein the enhancedp-polarized reflective coating comprises: a base layer positioned overthe portion of the at least one of the surfaces; at least one metalfunctional layer positioned over at least a portion of the base layer;and at least one phase adjustment layer positioned over at least aportion of the at least one metal functional layer; wherein the laminateexhibits a luminous transmittance using standard illuminate A (LTA)value of at least 70% and a reflectivity of the p-polarized radiation ofat least 5%, with Rfa* in the range of −2 to
 2. 2. The laminate of claim1, further comprising an anti-reflective coating comprising amulti-layer anti-reflective coating having one or more metal alloy oxidelayers and one or more metal oxide layers.
 3. The laminate of claim 2,wherein the multi-layer anti-reflective coating comprises: a first layerthat is a metal alloy oxide layer; a second layer that is a metal oxidelayer; a third layer that is a metal alloy oxide layer; and a fourthlayer that is a metal oxide top layer.
 4. The laminate of claim 2,wherein the enhanced p-polarized reflective coating is positioned overat least a portion of the second surface and the anti-reflective coatingis positioned over at least a portion of the fourth surface.
 5. Thelaminate of claim 1, wherein the base layer comprises: a first filmcomprising a metal alloy oxide film; and a second film positioned overthe first film, of the base layer, the second film of the base layercomprising an oxide mixture film.
 6. The laminate of claim 1, furthercomprising at least one sacrificial layer positioned between the atleast one metal functional layer and the at least one phase adjustmentlayer.
 7. The laminate of claim 1, wherein the enhanced p-polarizedreflective coating further comprises: a first metal functional layerpositioned over at least a portion of the base layer; a first phaseadjustment layer positioned over at least a portion of the first metalfunctional layer; and a second metal functional layer positioned over atleast a portion of the second metal functional layer.
 8. The laminate ofclaim 7, wherein the enhanced p-polarized reflective coating furthercomprises: a second phase adjustment layer positioned over at least aportion of the second metal functional layer; and a third metalfunctional layer position over at least a portion of the second phaseadjustment layer.
 9. The laminate of claim 7, wherein the enhancedp-polarized reflective coating further comprises a topcoat layerpositioned over at least a portion of the second metal functional layer.10. The laminate of claim 9, wherein the enhanced p-polarized reflectivecoating further comprises an overcoat positioned over at least a portionof the topcoat layer.
 11. The laminate of claim 7, wherein the enhancedp-polarized reflective coating further comprises a first sacrificiallayer positioned between the first metal functional layer and the firstphase adjustment layer.
 12. The laminate of claim 8, wherein theenhanced p-polarized reflective coating further comprises a secondsacrificial layer positioned between the second metal functional layerand the second phase adjustment layer.
 13. The laminate of claim 8,wherein the enhanced p-polarized reflective coating further comprises athird sacrificial layer positioned over at least a portion of the thirdmetal functional layer.
 14. The laminate of claim 1, wherein the baselayer has a thickness of 350-500 angstroms.
 15. A display system forprojecting an image comprising: a laminate having enhanced p-polarizedradiation reflecting properties comprising: a first ply comprising afirst surface and a second surface opposite the first surface, whereinthe first surface comprises an outer surface of the laminate; a secondply comprising a third surface adjacent the second surface and a fourthsurface opposite the third surface, wherein the fourth surface comprisesan inner surface of the laminate; an interlayer positioned between thefirst ply and the second ply; and an enhanced p-polarized reflectivecoating positioned over at least a portion of at least one of thesurfaces of the first ply and/or the second ply, wherein the enhancedp-polarized reflective coating comprises: a base layer positioned overthe portion of the at least one of the surfaces; at least one metalfunctional layer positioned over at least a portion of the base layer;and at least one phase adjustment layer positioned over at least aportion of the at least one metal functional layer; wherein the laminateexhibits a luminous transmittance using standard illuminate A (LTA)value of at least 70% and a reflectance of the p-polarized radiation ofat least 5%, with Rfa* in the range of −2 to 2; and a radiation sourcedirected at the laminate, the radiation source emitting radiationcomprising p-polarized radiation.
 16. The display system of claim 15,further comprising an anti-reflective coating comprising a multi-layeranti-reflective coating having one or more metal alloy oxide layers andone or more metal oxide layers.
 17. The laminate of claim 16, whereinthe multi-layer anti-reflective coating comprises: a first layer that isa metal alloy oxide layer; a second layer that is a metal oxide layer; athird layer that is a metal alloy oxide layer; and a fourth layer thatis a metal oxide top layer.
 18. The laminate of claim 16, wherein theenhanced p-polarized reflective coating is positioned over at least aportion of the second surface and the anti-reflective coating ispositioned over at least a portion of the fourth surface.
 19. Thelaminate of claim 15, wherein the base layer comprises: a first filmcomprising a metal alloy oxide film; and a second film positioned overthe first film, of the base layer, the second film of the base layercomprising an oxide mixture film.
 20. The laminate of claim 15, whereinthe enhanced p-polarized reflective coating further comprises: a firstmetal functional layer positioned over at least a portion of the baselayer; a first phase adjustment layer positioned over at least a portionof the first metal functional layer; and a second metal functional layerpositioned over at least a portion of the second metal functional layer.